Foamed Resin Wire Protector Weight Reduction
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Solution Overview
Problem
Existing wire protection techniques face challenges due to heavy resin molded protectors and constrained production processes, particularly with resin molding into routing configurations, which hinder the mounting and weight reduction of wire protectors.
Innovation Solution
A wire protecting protector made of foamed resin with a molded shape featuring a wire housing recess, a cover portion, and reinforcing films, allowing for reduced weight, easier mounting, and enhanced structural reinforcement, including a thinned portion and force-receiving areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin molded protector is used to protect wires, then the wire protection function is achieved, but the protector becomes heavy
Solution Approach 1:
The patent applies porous foam material instead of solid resin molding to create the wire protector. The foam structure provides the necessary protection function while significantly reducing weight due to its porous nature, directly resolving the contradiction between protection reliability and weight.
2Shape
If the wire harness is molded through resin molding into a routing configuration, then the routing configuration is achieved, but the production process becomes constrained
Solution Approach 1:
The patent divides the wire protecting system into separate components: the foam protector body and the wire harness. This segmentation allows the protector to be manufactured independently without complex resin molding constraints, while still achieving the desired routing configuration through the foam's inherent flexibility and moldability.
Solution Approach 2:
The patent changes the material parameter from rigid resin molding to flexible foam material. This parameter change enables easier manufacturing processes while maintaining the ability to achieve various routing configurations through the foam's properties and post-forming capabilities.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces the weight and mounting constraints of wire protectors while providing comprehensive wire protection and simplifying the production process, enabling lightweight, efficient wire protection with improved structural integrity.
Implementation Method 1
a wire protecting protector that is made of a foamed resin
Data Source
AI summary
An object of the present invention is to reduce the constraints on the mounting of a wire protecting protector to a wire, while achieving a reduction in the weight of the wire protecting protector. A wire protecting protector is made of a foamed resin and is formed in a shape having a wire housing recess capable of housing a wire, and a surface of the wire protecting protector that includes an inner circumferential surface on the wire housing recess side is a surface formed through molding. Preferably, a reinforcing film is formed on at least a part of the surface of the wire protecting protector.